Protective helmet wrap and related method of applying wrap to a protective helmet

ABSTRACT

A wrap for covering a protective helmet having an exterior shell that allows for personalization of the helmet in an effective and cost-efficient manner. The wrap has a flexible layer removably disposed around at least a portion of the exterior shell of the protective helmet such that said flexible layer is substantially flush with the exterior shell of the protective helmet. The flexible layer of the wrap may be made of a vinyl material. The wrap may have an additional layer positioned directly over the flexible layer, wherein the additional layer is made of a plastic material.

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/903,556, filed on Nov. 13, 2013, the disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates generally to protective helmets for football, baseball, softball, lacrosse, hockey, extreme sports and motor sports and, more particularly, to a cost-efficient, flexible and durable wrap or cover for a protective helmet that adheres substantially flush to the exterior shell of the protective helmet for use and is easily removable and replaceable.

BACKGROUND

American football, known in the United States as simply football, is the most popular sport in the United States. It is being played in youth leagues, high schools, colleges and professional leagues, the most popular being the National Football League (NFL). It is well known that football is a contact sport between the participants/players, which requires the players to wear pads over various body parts and protective football helmets on their heads. Furthermore, it is well known that a number of other sports such as baseball, softball, hockey, lacrosse, snowboarding, skiing, motor sports and extreme sports are popular throughout the United States and the world.

Although football helmets vary in size and exact shape to meet the physical dimensions of the particular player (and the player's position) wearing the helmet, each football helmet is substantially the same overall shape and contains the same basic elements. Generally, a football helmet includes a hard plastic exterior shell or base. The interior of the base includes padding such as multiple inflatable pockets to try to cushion the blows a player receives to his head to prevent brain injuries, skull fractures and other head injuries. The football helmet may have vents or openings near the top of the helmet as well as ear holes on each side of the helmet.

In addition, the exterior of the helmet includes a face mask made of one or more rigid bars in various arrangements depending on the player's position and preference. The helmet also includes a chin strap, which connects to each side of the helmet and goes under the player's chin as the name implies, i.e., beneath the facemask. The ends of the strap are typically attached directly to the football helmet to one or more snaps located on each side of the helmet. Each side of the strap should have equal tension such that the helmet is held snugly on the player's head during play.

Traditionally, most teams utilize a particular color and/or some type of logo or design on their football helmets to distinguish them from other teams. For example, the University of Michigan utilizes the famous winged helmet, which includes a distinctive two-toned painted design including a dark blue base and maize outward curves over the forehead forming a wing-shape. Other professional teams and colleges/universities utilize logos that may be attached to one or both sides of the helmet using adhesive as well as other distinctive paint schemes or logos on the football helmet to distinguish the helmets from other teams.

In recent years, a popular trend especially at a number of colleges and universities and the NFL is to utilize different helmet designs during the season. For example, the University of Oregon uses a different helmet with a new logo and color scheme almost every game of the college football season and, thus, may utilize over ten different helmets with different paint schemes and logos. In addition, a number of other colleges/universities often utilize an alternate helmet design during the season or for a special event/game, such as homecoming, military appreciation day, cancer awareness day or a “throwback” day where the school utilizes an uniform and helmet design from its past. The NFL also has breast cancer awareness month during the month of October wherein the teams incorporate a substantial amount of pink into their uniforms and “throwback” days where they utilize different helmets and jerseys honoring a particular year or time period.

While NFL teams and certain larger universities and colleges are able to afford to buy multiple helmets or have contracts with athletic apparel companies that agree to supply new helmets, most colleges and universities as well as high schools and youth teams cannot afford multiple helmets for each of their players. Instead, each player only has a single helmet to be used in practices and games throughout the season. A standard football helmet can cost over $400 and most colleges and universities have over 100 players, so a whole new set of helmets for the entire team can cost at least $40,000.

Since new helmets cannot be afforded by smaller colleges, high schools and youth leagues, the only way to change a helmet is to employ a different paint scheme on the helmet or utilize new adhesive logos on the helmet. However, both of these methods suffer from certain disadvantages. Namely, it is time consuming to paint over 100 helmets as each player requires a helmet having the same design and/or paint scheme. Furthermore, after the paint is applied to the helmet, the helmet cannot be used for a certain period of time as the paint must dry. This is especially problematic if the team practices in the same helmets as it uses in its games, which is common for many colleges and universities.

Although utilizing different logos is not necessarily as time consuming as painting the helmets, it is still a tedious process and the color of the helmet cannot be changed when simply applying a different logo to the side of the helmet. Moreover, if a completely different color and logo is desired, the helmet must be painted and allowed to dry before adding logos and/or decals to each helmet individually. Not only is the application process time consuming and expensive, but the removal process is equally difficult and tedious.

Accordingly, a need is identified for a protective helmet covering or wrap that may be applied directly to the exterior shell of the protective helmet to change exterior appearance of the helmet, i.e., the design, color and/or logo without making any permanent changes to the helmet. Furthermore, the protective helmet covering or wrap should not only be aesthetically pleasing, but sufficiently durable to withstand the rigors applied to the helmet and wrap or cover during the athletic event. Finally, the protective helmet covering or wrap should be both cost-efficient and easy to apply to a protective helmet and equally easy to remove from the helmet.

SUMMARY

In accordance with one aspect of the disclosure, a wrap for covering a protective helmet having an exterior shell is disclosed. The wrap has a flexible layer removably disposed around at least a portion of the exterior shell of the protective helmet such that said flexible layer is substantially flush with the exterior shell of the protective helmet. The wrap may have an additional layer positioned directly over the flexible layer. The layers may be constructed of different materials, such as a vinyl material for the flexible layer and a plastic material for the additional layer. The wrap may also include a final layer constructed of the same material as the additional layer. In some embodiments, the wrap is positioned around substantially the entirety of the exterior shell of the protective helmet.

In yet another aspect of the disclosure, a removable cover for an athletic helmet having a protective shell is disclosed. The removable cover has a printable film for positioning over the protective shell of the athletic helmet and a laminate material for substantially covering the printable film. The printable film may be clear and/or configured to be imprinted with a logo, while the laminate material may have a glossy finish. The removable cover may include an adhesive layer for attaching directly to the protective shell of the athletic helmet. Furthermore, the removable cover may have a thickness of less than 0.10 mm. Finally, the removable cover may be shaped to correspond with the shape of the protective shell of the athletic helmet.

Another related aspect of this disclosure is a method of applying a wrap to a football helmet. The method includes providing a layer of vinyl material and transferring the layer of vinyl material to the football helmet. Other steps that may be used in this method of applying a wrap to a football helmet, include laminating the vinyl layer, printing a layer of vinyl material, heating, stretching and sealing the layer of vinyl material, adding an adhesive to the football helmet and removing any excess vinyl from the layer of vinyl material that is not transferred directly to the football helmet.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of this disclosure, and together with the description serve to explain the principles of the disclosure. In the drawings:

FIG. 1 is a side view of a representative football helmet;

FIG. 2 is a front view of a representative football helmet;

FIG. 3 is a back view of a representative football helmet;

FIG. 4 is a side view of a football helmet with a wrap covering the helmet forming one aspect of the disclosure;

FIG. 5 is a front view of the football helmet with the wrap covering the helmet forming one aspect of the disclosure;

FIG. 6 is a back view of the football helmet with the wrap covering the helmet forming one aspect of the disclosure;

FIGS. 7 a and 7 b are a partial cut-away top view of the wrap and an enlarged side view of the wrap;

FIG. 8 is a front view of a barrel applicable for use in applying the wrap to the football helmet forming one aspect of the disclosure;

FIG. 9 is a top view of a hoop applicable for use in applying the wrap to the football helmet forming one aspect of the disclosure;

FIGS. 10 a-10 c are various views of the wrap and the barrel used in applying the wrap to the football helmet forming one aspect of the disclosure; and

FIG. 11 is a block diagram of the method of applying the wrap to the football helmet forming one aspect of the disclosure.

DETAILED DESCRIPTION

In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and like numerals represent like details in the various figures. Also, it is to be understood that other embodiments may be utilized and that process or other changes may be made without departing from the scope of the disclosure. The following detailed description is not to be taken in a limiting sense, and the scope of the invention is defined only by the appended claims and their equivalents. In accordance with the disclosure, a helmet covering or wrap is hereinafter described. The helmet covering or wrap allows the personalization of the athletic helmets in an aesthetically pleasing, yet efficient and cost-effective manner.

As shown in FIGS. 1-3, a representative football helmet 10 is illustrated. As plainly shown in these figures, the football helmet 10 is substantially the same shape and includes the same features as a traditional football helmet. For example, the football helmet has a rigid, protective exterior shell or base 20, an interior portion with padding 30, a facemask 40, a plurality of vents/openings 50 and ear holes 60. The chin strap and related snaps on the helmet are not shown. It should be appreciated that the helmet shown in FIGS. 1-3 is a solid, single color with no logos or other indicia on the exterior shell. As discussed above, each team's helmet may be designed in a number of different colors, color patterns with various logos or other indicia located on the exterior shell.

Turning to FIGS. 4-6, the same football helmet illustrated in FIGS. 1-3 is shown with a cover or wrap 70 positioned over substantially the entirety of the protective shell 20 of the helmet 10. As illustrated, the wrap 70 in made of a unitary construction and conforms generally to the shape of the exterior shell 20 of the helmet 10. As further illustrated, the cover or wrap 70 is substantially flush over the shell of the helmet such that there are no air bubbles or loose pockets of air. The cover or wrap 70 has a different color/pattern (indicated by the grid-like pattern) than the plain color of the representative helmet along with an eagle logo 80 positioned on each side of the helmet. The particular color scheme and design is not intended to be limiting as the cover or wrap may be made with nearly any design and color scheme and may be left up to the imagination of the buyer or designer of the cover or wrap.

In more detail, the cover or wrap 70 is made of a first flexible layer 90 configured to be removably disposed around at least a portion of the exterior shell of the protective helmet. The first layer 90 may be a printable vinyl material or film, cast vinyl, vinyl polymer or vinyl derivative. Advantageously, the vinyl material comprising the first layer 90 provides sufficient flexibility. Specifically, the vinyl material comprising the first layer 90 has superior conformability and elastic properties such that it may be applied substantially flush with the exterior shell of the helmet such that it easily conforms to the shape and contour of the exterior shell of the helmet.

The first layer 90 may be stretched around the entirety of the exterior shell of the helmet 10. As a result, installation is relatively easy and no air channels or bubbles exist between the first layer of the wrap and the exterior shell of the helmet. Of course, it should be appreciated that the first layer 90 does not have to stretch around the entirety of the exterior shell of the helmet. For example, the first layer 90 may only be applied to a portion of the exterior shell of the helmet, such as only the left-side or right-side of the helmet. As a result, the first layer 90 may be used to create a two-tone or different colored pattern on the helmet, such as the one side of the helmet that is not covered with the first layer has the color of the shell of the helmet while the other side of helmet covered with the first layer 90 has the color of the wrap.

Advantageously, the vinyl material may be imprinted via an inkjet or laser printer with essentially any desired color, logo and/or design, which avoids the additional step of placing stickers or decals with a logo on the helmet after the printing process is complete. The vinyl material is durable such that it withstands normal wear and tear from contact that is typical in sports, such as football. In one particular embodiment, the vinyl film is 3M IJ380Cv3 vinyl. The vinyl makes up the base layer for the cover or wrap and may be applied to the helmet with or without a pressure-activated adhesive for easy sliding and positioning over the helmet. The vinyl material should be relatively thin to substantially conform to and wrap substantially around the entirety of the helmet. Typically, the thickness of the vinyl material is between 0.05 mm and 0.10 mm. The first layer 90 is durable enough to be used by itself on the helmet without additional layers, which are discussed below.

The cover or wrap 70 may also include a second layer 100 positioned substantially entirely over the first layer 90. The second layer 100 is typically made of a clear plastic or clear vinyl film, such as a laminate material to improve the strength, stability, appearance and other properties of the cover or wrap. The laminate is typically a thin, extremely flexible film that provides additional protection for the first layer of the cover or wrap. The second layer 100 also improves the visual appearance of the wrap or cover 70 by providing a high resolution glossy finish. Namely, the second layer 100 or laminate protects the graphic design and color scheme on the first layer 90.

In one particular embodiment, the laminate may be 3M Overlaminate 8580, which has excellent resistance to water. Typically, the laminate is applied after a sufficient amount of time has elapsed after printing the first layer 90. The second layer 100 may be applied in various manners, including a cold roll lamination method or a printer. In addition, an optional third layer 110 may be applied over the second layer 100 of the wrap 70 as illustrated in FIGS. 7 a and 7 b. The third layer 110 may be used for improved durability and may be constructed of the same material as the second layer, i.e., a laminate material. Furthermore, the cover or wrap 70 may be easily removed from the helmet without the need for heat and/or chemicals. Instead, the cover or wrap 70 may be easily peeled off the exterior shell of the helmet like an adhesive bandage by hand.

With respect to FIG. 11, the method of applying the football helmet cover or wrap 70 to the helmet 10 is illustrated. The first step 170 is the selection of the design for the cover or wrap that will be placed over the football helmet. As discussed above, it should be appreciated that essentially any design and/or color scheme may be selected. Once the design and/or color scheme is selected, the design is typically generated 180 on a computer application. Of course, if the helmet is merely a single color scheme with no particular design element, no design needs to be generated on the computer application and instead the particular color of vinyl may simply be selected.

The next step 190 involves printing the first vinyl layer with or without a design element. Generally, vinyl is produced in large rolls, which may be fed to a laser or inkjet printer. The printer is used to decorate the first or vinyl layer with the particular color and/or design scheme. After the first layer is printed, the next step 200 involves a lamination process wherein the vinyl sheet (or first layer) is laminated with a second layer (or an additional lamination step may be used to add a third layer if desired) to provide a glossy high resolution finish to the vinyl wrap or cover and to protect the design of the first layer. As discussed above, a cold roll lamination method, a printing process or other suitable lamination method may be used.

After the lamination step 200, the wraps or covers (which are typically in the form of large sheets) undergo a cutting step 210. This process involves cutting the vinyl wrap or cover into appropriate sized sheets. Each sheet typically may be cut and sized such that it may be used for covering two different football helmets. Of course, it should be appreciated that the sheets may be cut into any desired size.

Once the wraps are cut into appropriate sized sheets for applying to the helmet, the final steps involve transferring 230 and securing 240 the wrap or cover to the helmet. Prior to these steps, an adhesive may be applied 220 to the helmet to further aid in the wrap or cover firmly adhering to the helmet. As shown in FIG. 8, in one particular embodiment, a cylindrical plastic barrel 120 having a circular opening 130 at one end is used to assist in the transferring step 230 and securing step 240 illustrated in FIGS. 10 a-10 c.

At this point in the process, the wrap or cover 70 is in the form of a sheet or multi-layered sheet. The wrap or cover 70 is typically transferred or placed over the open end, i.e., the circular opening 130 of the barrel 120 as shown in FIG. 10 a. Subsequently, the wrap may be secured to the barrel by using duct or masking tape or some other adhesive or securing means as shown in FIG. 10 b. Once the wrap or cover is secured to the barrel, the next steps are heating 250, stretching 260 and sealing 270 the wrap or cover 70. As heat is applied, the football helmet 10 is firmly pressed on the wrap or cover as shown in FIG. 10 c. A vacuum may be used to further stretch and seal the wrap to the helmet.

In an alternative method to using a barrel, a hoop 140 (as illustrated in FIG. 9) may be used to assist in the transferring process. The hoop 140 may be made of different materials, including but not limited to wood or metal. The hoop may have two rings including an inner ring 150 and an outer ring 160. The outer ring 160 is capable of being clamped to the inner ring 150 via a fastener or the like. Similar to the process utilizing a barrel 120 discussed above, the wrap or cover 70 in the form of a sheet is typically transferred or placed over the inner ring 150 of the hoop 140. Once the wrap is secured over the inner ring 150, the outer ring 160 may be clamped to the inner ring 150 to keep the wrap secure. Once the wrap or cover is secured to the hoop, the next steps are heating, stretching and sealing the wrap or cover 70. As heat is applied, the football helmet 10 is firmly pressed on the wrap or cover 70. A vacuum may be used to further stretch and seal the wrap to the helmet.

In one embodiment, the wrap or cover may be transferred onto the helmet by removing the back from the laminated sheet of vinyl and the cover/wrap is fit snugly over the helmet such that there should not be any wrinkles, folds or air bubbles. Instead, the wrap or cover fits directly over the helmet in a substantially snug manner, i.e., form-fitting or flush to the helmet. Typically, regardless of the method used in transferring the wrap to the helmet, once the wrap or cover is sealed to the helmet, the vinyl covering the ear holes must be removed or “punched out” 280 which can be completed manually or by an automated process with a machine. Furthermore, the removing step 280 may include a trimming step to cut around the edges of the football helmet to eliminate any excess vinyl that is not needed to cover the helmet, which may be completed by scissors, a knife or the like.

It should be appreciated that the final securing steps discussed above were described as being completed manually with tools used for stretching, heating, applying and sealing the wrap to the helmet. Of course, these steps may also be completed automated via a machine to cut down on time and improve efficiency. For example, a machine may assist in the transferring process from the vinyl sheet (laminated or not) to the helmet to further speed up and streamline the process. The machine is automated to accomplish stretching of the cover for application to the helmet, such as applying heat and using a vacuum to stretch the wrap to allow it to contour around the helmet and sealing the wrap to the helmet.

As shown in FIGS. 4-6, it should be appreciated that the football wrap or cover may completely cover substantially the entirety of the exterior of the football helmet. However, as discussed above, the wrap may only cover a portion or half of the helmet to create a dual color pattern. For example, the half not covered by the wrap would maintain the color of the helmet and the half covered by the wrap would be the color of the wrap. It should be appreciated that the wrap or cover is typically applied to the helmet without a facemask 40 attached thereto. Thus, before the wrap is applied to the helmet, the facemask 40 is typically removed from the helmet. Accordingly, once the football helmet wrap or cover is completely secured around the helmet and the excess vinyl is trimmed or cut, the facemask 40 may be attached or re-attached 290 to the helmet 10 and the helmet is ready to use within minutes.

Unlike painting or buffing helmets which takes hours and prevents the use of the helmets for a substantially period of time, this process may be completed in minutes rather than hours. Furthermore, a single football helmet may be changed with a cover into numerous designs, so it is possible to change the design of the helmet each week during the season while only employing one helmet per player.

It should be appreciated that the vinyl and laminate materials are relatively inexpensive materials so the football helmet wraps or covers are not particularly expensive for colleges and high schools to employ. Once the football helmet wrap or cover is used, it may be easily removed by simply peeling the vinyl cover off the helmet like an adhesive bandage to return to the football helmet to its original state or to apply a differently designed or colored cover or wrap. It should be further appreciated that the wrap and process for applying the wrap to a helmet discussed herein are not limited to football helmets, but may also be used on other protective helmets, such as baseball, softball, lacrosse and hockey helmets, motorcycle and racing car helmets as well as other extreme and outdoor sports helmets, such as skiing and snowboarding helmets.

The foregoing descriptions of various embodiments are provided for purposes of illustration, and are not intended to be exhaustive or limiting. Modifications or variations are also possible in light of the above teachings. The embodiments described above were chosen to provide the best application to thereby enable one of ordinary skill in the art to utilize the disclosed inventions in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention. 

1. A wrap for covering a protective helmet having an exterior shell, comprising: a flexible layer removably disposed around at least a portion of the exterior shell of the protective helmet such that said flexible layer is substantially flush with the exterior shell of the protective helmet.
 2. The wrap according to claim 1, further comprising an additional layer positioned directly over the flexible layer.
 3. The wrap of claim 1, wherein the flexible layer is made of a vinyl material.
 4. The wrap of claim 1, wherein the additional layer is made of a plastic material.
 5. The wrap of claim 1, wherein the layers are constructed of different materials.
 6. The wrap of claim 1, further comprising a final layer constructed of the same material as the additional layer.
 7. The wrap of claim 1, wherein the wrap is positioned around substantially the entirety of the exterior shell of the protective helmet.
 8. A removable cover for an athletic helmet having a protective shell, comprising: a printable film for positioning over the protective shell of the athletic helmet; and a laminate material for substantially covering the printable film.
 9. The removable cover of claim 8, wherein the printable film is configured to be imprinted with a logo.
 10. The removable cover of claim 8, wherein the laminate material is clear.
 11. The removable cover of claim 8, further comprising an adhesive layer attaching directly to the protective shell of the athletic helmet.
 12. The removable cover of claim 8, wherein the cover has a thickness of less than 0.10 mm.
 13. The removable cover of claim 8, wherein the cover is shaped to correspond with the shape of the protective shell of the athletic helmet.
 14. The removable cover of claim 8, wherein the laminate material has a glossy finish.
 15. A method of applying a removable wrap to a football helmet, comprising: providing a layer of vinyl material; and transferring the layer of vinyl material directly to the football helmet.
 16. The method of claim 15, further comprising laminating the layer of vinyl material.
 17. The method of claim 14, wherein the providing step includes printing a layer of vinyl material.
 18. The method of claim 14, wherein the transferring step includes heating, stretching and sealing the layer of vinyl material.
 19. The method of claim 14, wherein the transferring step includes adding an adhesive to the football helmet.
 20. The method of claim 14, further comprising after the transferring step, removing any excess vinyl from the layer of vinyl material that is not transferred directly to the football helmet. 